Toilet paper roll and method of manufacturing the paper roll

ABSTRACT

A toilet paper roll capable of remarkably reducing unwinding noise when used as a toilet paper roll, improving a refuse treatment measure by easily crushing and disposing off a thick core of the paper roll, reducing the production cost of the paper roll, flowing the thick core into a toilet and, when used, allowed to be recovered generally to a circular section form for practical use while the storage and transportation costs of the paper roll are reduced, comprising the thick core( 1 ) made of thin paper of approx. 4 cm in outside diameter and toilet paper( 2 ) generally softly wound on the thick core( 1 ) from the first to the last, wherein the thic kcore( 1 ) is formed flat as required, and the toilet paper( 2 ) is also formed in a flat elliptic shape so as to follow up the flat thick core( 1 ).

TECHNICAL FIELD

[0001] The present invention relates to a toilet paper roll having athick tubular core which is mountable on a thick shaft portion of atypical household toilet paper roll holder, and a method ofmanufacturing the paper roll.

BACKGROUND ART

[0002] In a typical conventional toilet paper roll, the toilet paper anda paper tube (core) are provided separately, the core being a tubularbody formed from a thick paper material made of cardboard with adiameter of approximately 3.8 cm up to approximately 4.5 cm. In recentyears, on the other hand, a so-called core-less toilet paper roll,comprising the toilet paper and a core formed from one part of thetoilet paper in the central part of the roll into which the toilet paperis wound, has been researched, developed, and has arrived on the market.

[0003] Two types of this core-less toilet paper roll exist: a type inwhich the inner diameter of the hole in the center of the roll isparticularly small, and a type in which the inner diameter of the holeis large so as to be mountable on a thick shaft portion of a typicalhousehold toilet paper roll holder. The type in which the inner diameterof the hole is small is used when the diameter of the shaft portion ofthe holder also has a small diameter, and is therefore unfavorable sinceit cannot be used with the thick shaft portion of a toilet paper rollholder used in a typical household.

[0004] Regardless of whether the inner diameter of the central hole ofthe roll is large or small, almost all of these core-less toilet paperrolls of both kinds are wound substantially tightly from the beginningto the end [of the roll], and there has never existed a roll which iswound loosely. This is because it is believed that in order to form thecore from one part of the toilet paper in the center of the wound roll,winding the paper tightly from first to last is a necessary requirement(see Japanese Utility Model Publication H6-47356). Consequently, generalmarkets and users have requested the development of a loosely-wound,loose type core-less toilet paper roll.

[0005] In response to these requests and so on, a loose type core-lesstoilet paper roll has been developed in which the entire roll is woundsubstantially loosely, and the initial turns in the central part of theroll are adhered with an adhesive to form a tubular core portion.Although not specified as loose type, an adhered tubular core portion isdisclosed in Japanese Patent Application Laid-Open H7-2395. Althoughsuch tubular core portions are formed by adhering the point at which thetoilet paper is initially loosely wound using an adhesive, there existsno such core-less toilet paper roll that is produced systematically. Theouter appearance of the shape of the hole of these tubular core portionsis such that the initially wound section generally appears highlyirregular, as if the shape of the inner diameter of the hole has beendamaged, and it has not been easy to bring familiarity to such productson the market. It is technically difficult to systematically mold thecentral portions of the roll at the initially wound section of suchloose type core-less toilet paper rolls. Another disadvantage is thatthe machine for manufacturing these loose type core-less toilet paperrolls is of a special specification, meaning that such toilet paperrolls are comparatively extremely expensive to produce.

[0006] Furthermore, a trend has arisen in recent years in which womenand the like have taken a great dislike to the rattle-like unwindingnoise that is generated during toilet paper roll use. Consequently,there have been requests for the development of a toilet paper roll inwhich no unwinding noise, or an extremely soft unwinding noise, isproduced during use.

[0007] Also, processing of marketed paper toilet paper rolls, andparticularly of the paper tube which forms the core in the centralportion of the roll following use thereof, is considered a problem. Morespecifically, since the core is made of a thick cardboard papermaterial, the core is not easy for women and children to crush, and thusdisadvantages arise such as the core being rather bulky to dispose of asrefuse. Furthermore, the paper tube cores of these toilet paper rollsare thrown into the lavatories of public toilets and the like, causingmany cases of toilet blockages, and it is also to take measures againstpaper tube cores that the present applicant has developed a core-lesstype toilet paper roll. A product has also been developed in which thepaper tube core can be flushed down the toilet, but this product isexpensive and not suited to general use.

[0008] A toilet paper roll in the form of a flat ellipse has also beendeveloped as a product (Japanese Utility Model Application Laid-OpenH7-25894), but since the paper tube core is formed from a thickcardboard paper material, a great deal of force is required to work theproduct into a flat form, and thus a special device has to be used(Japanese Patent Publications H5-21814 and H6-84220). The product istherefore disadvantaged in that the manufacturing cost per unit is high.Moreover, as is illustrated in FIG. 43, the paper tube core formed fromthick cardboard paper material does not become circular during use, andthus even when mounted on the thick shaft part of a typical householdtoilet [paper roll] holder, inconveniences arise such as the generationof excessively loud noise.

DISCLOSURE OF THE INVENTION

[0009] In order to solve the aforementioned problems, the presentinvention comprises a toilet paper roll which is constituted by a thicktubular core manufactured from thin paper and having a diameter ofapproximately 4 cm and toilet paper 2 which is wound substantiallyloosely around this thick tubular core from beginning to end. Bymounting this on the thick shaft portion of a typical household toiletpaper roll holder, unwinding noise can be reduced considerably, refuseprocessing of the thick tubular core can be performed favorably, thethick tubular core can be manufactured at a reasonable cost, whereby themanufacturing costs of the toilet paper roll can also be reduced, andmanufacturing costs can be improved in comparison with a toilet paperroll that is wound entirely loosely up to the core.

[0010] The present invention also comprises a toilet paper rollconstituted by a thick tubular core manufactured from thin paper andhaving a diameter of approximately 4 cm and toilet paper which is woundaround this thick tubular core tightly in the initial several turns andthereafter wound substantially loosely to the end, thereby being woundsubstantially loosely as a whole. Although the toilet paper is woundaround the thick tubular core tightly in the initial several turns andthereafter wound substantially loosely to the end, as a whole the toiletpaper is wound substantially loosely, and therefore has the sameconstitution and exhibits the same effects as the aforementioned toiletpaper roll, which is wound substantially loosely from beginning to end.The present invention further comprises a toilet paper roll constitutedby a thick tubular core which is manufactured from thin paper and has adiameter of approximately 4 cm, and toilet paper which is wound aroundthis thick tubular core tightly for several turns at a part excludingthe initial part and thereafter wound substantially loosely, therebybeing wound substantially loosely as a whole. Here also, being woundaround the thick tubular core tightly for several turns at a partexcluding the initial part and thereafter wound substantially loosely,and thereby being wound substantially loosely as a whole, this toiletpaper roll has the same constitution and exhibits the same effects asthe aforementioned toilet paper roll, which is wound substantiallyloosely from beginning to end.

[0011] In the aforementioned three constitutions of the presentinvention, the thick tubular core is constituted by percolation paper.As a result, the thick tubular core differs from a conventionalcardboard paper tube core in that its strength is a great deal weaker,and in that percolation paper has a water-soluble property such thattoilet blockages can be avoided even when the thick tubular core whichremains on the thick shaft portion of a typical household toilet paperroll holder after use of the toilet paper roll is flushed down thetoilet (see FIG. 9). Thus, the toilet paper roll is extremely convenientin that after each use thereof, the thick tubular core is not disposedof as general refuse.

[0012] The present invention is also comprised of a toilet paper rollwhich is constituted by a thick tubular core manufactured from thinpaper and having a diameter of approximately 4 cm and toilet paper whichis wound substantially loosely around this thick tubular core frombeginning to end, wherein this thick tubular core is formed into a flatshape and the toilet paper is also formed into a flat elliptical shapein compliance with the flat thick tubular core. Thus, even though thethick tubular core is flat, the thick tubular core is made of thinpaper, and so when the toilet paper roll is mounted onto the thick shaftportion of a toilet paper roll holder, it can be returned to asubstantially perfect circle which is adequate for use due to thesynergistic action between the loose toilet paper and the fact thatalmost no pressure is applied even when the thick tubular core isflattened. Further, since the toilet paper roll has a flat ellipticalform, advantages are obtained over a conventional perfectly circulartoilet paper roll in that space can be greatly economized such thatstorage and transportation costs can be reduced.

[0013] The present invention is further comprised by a toilet paper rollwhich is constituted by a thick tubular core which is manufactured fromthin paper and has a diameter of approximately 4 cm and toilet paperwhich is wound around this thick tubular core tightly in the initialseveral turns and thereafter wound substantially loosely to the end,thereby being wound substantially loosely as a whole, wherein the thicktubular core is formed into a flat shape and the toilet paper is alsoformed into a flat elliptical shape in compliance with the flat thicktubular core, or which is constituted by a thick tubular core which ismanufactured from thin paper and has a diameter of approximately 4 cmand toilet paper which is wound around this thick tubular core tightlyfor several turns at a part excluding the initial part and thereafterwound substantially loosely, thereby being wound substantially looselyas a whole, wherein the thick tubular core is formed into a flat shapeand the toilet paper is also formed into a flat elliptical shape incompliance with the flat thick tubular core.

[0014] The present invention is further comprised by a toilet paper rollconstituted by a thick tubular core which is manufactured from thinpaper and has a diameter of approximately 4 cm and toilet paper which iswound substantially loosely around this thick tubular core frombeginning to end, wherein the thick tubular core is formed into asubstantially flat shape having fig-like expanded portions on bothsides, and the toilet paper is also formed into a flat elliptical shapein compliance with the substantially flat thick tubular core. Thus, eventhough the thick tubular core is flat, the thick tubular core is made ofthin paper, and so when the toilet paper roll is mounted onto the thickshaft portion of a toilet paper roll holder, it can be returned to asubstantially perfect circle which is adequate for use due to thesynergistic action between the loose toilet paper and the fact thatalmost no pressure is applied even when the thick tubular core isflattened and has fig-like expanded portions on both sides, and due tothe absence of kinks because of the existence of the expanded parts.Further, since the toilet paper roll has a flat elliptical form,advantages are obtained over a conventional perfectly circular toiletpaper roll in that space can be greatly economized such that storage andtransportation costs can be reduced.

[0015] The present invention is further comprised by a toilet paper rollof the aforementioned constitution which is formed such that during theformation of the toilet paper into a flat elliptical shape, there existsno compression yield point at which, when a compressive load of aprescribed value is applied to a semi-manufactured toilet paper roll,the amount of displacement increases even without applying increasedpressure beyond the prescribed value, and such that the amount ofdisplacement only increases with the gradual application of pressure ofhalf or less than half of the compressive load of the prescribed value.Thus, the semi-manufactured toilet paper roll can be systematicallyformed into a flat elliptical shape with the application of slightpressure of half or less than half of the compressive load of theprescribed value. In particular, since the compression yield point K, atwhich the amount of displacement increases even without the applicationof further pressure, does not exist upon reaching the compressive loadof the prescribed value, no large machine for forming the toilet paperroll into a flat elliptical shape is necessary, and since little forceis required to return the toilet paper roll to its original circularshape, packaging of the flat elliptical toilet paper rolls can be easilyachieved using a simple device or the like. Conversely, when there is acardboard paper tube core such as in marketed items a and b in FIGS. 36and 44, the compressive yield point K, having a prescribed value whichis a large compressive load, exists, and therefore a large force isrequired to compress the core. As a result, when the toilet paper rollis placed in a bag or the like, great repulsive force is necessary toreturn the toilet paper roll from an elliptical form to a circular form,and a large sealing device must be employed. These conventionalinconveniences have been eliminated by the present invention.

[0016] The present invention further comprises a toilet paper rollmanufacturing method which comprises the steps of: manufacturing asemi-manufactured toilet paper roll comprising a thick tubular corewhich is made of thin paper and which has a diameter of approximately 4cm, and toilet paper which is wound substantially loosely as a wholearound this thick tubular core; fixing and supporting thissemi-manufactured toilet paper roll in a substantially outer diametricalposition with facing pressing support plates; pressing thesemi-manufactured toilet paper roll inward at a substantially centralposition from the two substantially orthogonal directions to thedirection of spacing between the two pressing support plates usingpressing portions on the ends of hydraulic cylinders; forming the entirethick tubular core into a substantially flat shape while formingfig-like expanded portions on the two end positions of the substantiallyflat thick tubular core; and also forming the toilet paper into a flatelliptical shape in compliance with the substantially flat thick tubularcore. The advantage here is that since the semi-manufactured toiletpaper roll is supported, the toilet paper roll is prevented frombecoming flat, and in this state, due to the synergistic action betweenthe facts that the toilet paper roll is only pressed inward at thecenter thereof, the thick tubular core is manufactured from thin paper,and the toilet paper is wound substantially loosely as a whole, thefig-like expanded portions can be formed with ease.

[0017] The present invention further comprises a toilet paper rollmanufacturing method which comprises the steps of: manufacturing asemi-manufactured toilet paper roll comprising a thick tubular corewhich is made of thin paper and which has a diameter of approximately 4cm, and toilet paper which is wound substantially loosely as a wholearound this thick tubular core; stretching the thick tubular core byinserting two hole-widening round bars therein; pressing the thicktubular core inward from both sides using hydraulic cylinders indirections which are orthogonal to the spacing between the twohole-widening round bars while forming the thick tubular core into aflat elliptical shape; and forming the entire thick tubular core into asubstantially flat shape by forming fig-like expanded portions on bothsides of the thick tubular core while also forming the toilet paper intoa flat elliptical shape in compliance with the substantially flat thicktubular core. The advantage here is that due to the synergistic actionamong the two hole-widening round bars, the thin paper thick tubularcore, and the toilet paper which is wound substantially loosely as awhole, the fig-like expanded portions can be molded comparativelyeasily. A further advantage is that this toilet paper roll can be formedinto a substantially circular form with no kinks in the thick tubularcore thereof upon mounting onto the thick shaft portion of a toiletpaper roll holder.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018]FIG. 1A is a perspective view of a toilet paper roll of a firstembodiment of the present invention;

[0019]FIG. 1B is a partially enlarged perspective view of FIG. 1A;

[0020]FIG. 1C is a side view of FIG. 1A and a rendering of the flatelliptical form during storage and the like [of the toilet paper roll];

[0021]FIG. 2A is a side view of the first embodiment of the presentinvention;

[0022]FIG. 2B is a partially enlarged view of FIG. 2A;

[0023]FIG. 2C is a partial schematic view of FIG. 2A;

[0024]FIG. 3A is a side view of a second embodiment of the presentinvention;

[0025]FIG. 3B is a partially enlarged view of FIG. 3A;

[0026]FIG. 3C is a partial schematic view of FIG. 3A;

[0027]FIG. 4A is a side view of a third embodiment of the presentinvention;

[0028]FIG. 4B is a partially enlarged view of FIG. 4A;

[0029]FIG. 4C is a partial schematic view of FIG. 4A;

[0030]FIG. 5A is a view showing the state of unwinding of the presentinvention;

[0031]FIG. 5B is an enlarged cross-sectional view of the S portion ofFIG. 5A, and a view showing a state in which a sound source iseliminated or reduced;

[0032]FIGS. 6A and 6B are views showing the state of the central portionof the toilet paper roll during an unwinding process of the presentinvention;

[0033]FIGS. 7A and 7B are views showing the state of the central portionof the toilet paper roll during the unwinding process of a conventionalproduct;

[0034]FIG. 8A is a view showing a normal process to crush a thicktubular core of the present invention;

[0035]FIG. 8B is a view showing another state in which the thick tubularcore of the present invention is crushed;

[0036]FIG. 8C is a view showing a further state in which the thicktubular core of the present invention is crushed;

[0037]FIGS. 9A through 9E are views showing states of flushing the thicktubular core of the present invention down a toilet;

[0038]FIG. 10A is a perspective view of a semi-manufactured toilet paperroll of a fourth embodiment of the present invention;

[0039]FIG. 10B is a partially enlarged perspective view of FIG. 10A;

[0040]FIG. 10C is a perspective view of the toilet paper roll of thefourth embodiment of the present invention as a finished product, and arendering of the semi-manufactured product thereof;

[0041]FIG. 11A is a side view of the semi-manufactured toilet paper rollof the fourth embodiment of the present invention, and a rendering ofthe finished product thereof;

[0042]FIG. 11B is a partially enlarged view of FIG. 11A;

[0043]FIG. 11C is a partial schematic view of FIG. 11A;

[0044]FIG. 12A is a side view of a semi-manufactured toilet paper rollof a fifth embodiment of the present invention, and a rendering of afinished product thereof;

[0045]FIG. 12B is a partially enlarged view of FIG. 12A;

[0046]FIG. 12C is a partial schematic view of FIG. 12A;

[0047]FIG. 13A is a side view of a semi-manufactured toilet paper rollof a sixth embodiment of the present invention, and a rendering of afinished product thereof;

[0048]FIG. 13B is a partially enlarged view of FIG. 13A;

[0049]FIG. 13C is a partial schematic view of FIG. 13A;

[0050]FIGS. 14A through 14D are views of a process to mount the toiletpaper rolls of the fourth through sixth embodiments of the presentinvention on a thick shaft of a toilet paper roll holder by returningthe toilet paper roll to its original circular shape;

[0051]FIG. 15A is a perspective view of a semi-manufactured toilet paperroll of a seventh embodiment of the present invention;

[0052]FIG. 15B is a partially enlarged perspective view of FIG. 15A;

[0053]FIG. 15C is a perspective view of the toilet paper roll of theseventh embodiment of the present invention as a finished product, and arendering of the semi-manufactured product thereof;

[0054]FIG. 16A is a side view of the semi-manufactured toilet paper rollof the seventh embodiment of the present invention, and a rendering ofthe finished product thereof;

[0055]FIG. 16B is a partially enlarged view of FIG. 16A;

[0056]FIG. 16C is a partial schematic view of FIG. 16A;

[0057]FIG. 17A is a side view of a semi-manufactured toilet paper rollof an eighth embodiment of the present invention, and a rendering of afinished product thereof;

[0058]FIG. 17B is a partially enlarged view of FIG. 17A;

[0059]FIG. 17C is a partial schematic view of FIG. 17A;

[0060]FIG. 18A is a side view of a semi-manufactured toilet paper rollof a ninth embodiment of the present invention, and a rendering of afinished product thereof;

[0061]FIG. 18B is a partially enlarged view of FIG. 18A;

[0062]FIG. 18C is a partial schematic view of FIG. 18A;

[0063]FIGS. 19A through 19D are views of a process to mount the toiletpaper rolls of the seventh through ninth embodiments of the presentinvention on a thick shaft of a toilet paper roll holder by returningthe toilet paper roll to its original circular shape;

[0064]FIG. 20A is a simplified plan view showing the final stage of themanufacturing process for the toilet paper roll of the seventh to ninthembodiments in a third manufacturing method of the present invention;

[0065]FIG. 20B is a plan view showing the main components of FIG. 20A;

[0066]FIGS. 21A through 21F are views showing the process for workingthe toilet paper roll of the seventh to ninth embodiments into a flatellipse in the third manufacturing method of the present invention;

[0067]FIGS. 22A through 22E are views showing the process for workingthe toilet paper roll of the seventh to ninth embodiments into a flatellipse in the third manufacturing method of the present invention;

[0068]FIG. 23 is a perspective view of the main components used inmanufacturing the toilet paper roll of the seventh to ninth embodimentsin the third manufacturing method of the present invention;

[0069]FIG. 24A is a front view of the main components used inmanufacturing the toilet paper roll of the seventh to ninth embodimentsin a fourth manufacturing method of the present invention;

[0070]FIG. 24B is a view showing the manufacturing method of FIG. 24A;

[0071]FIG. 25A is a table of the rate of change under load categorizedby winding type;

[0072]FIG. 25B is a simplified view of a measurement method formeasuring the rate of change under load;

[0073]FIG. 25C is a graph comparing the rates of change under loadcategorized by winding type;

[0074]FIG. 26 is a table of the measurement data for the rate of changeunder load of the product implemented in the present invention;

[0075]FIG. 27 is a table of the measurement data for the rate of changeunder load of a slightly loose toilet paper roll;

[0076]FIG. 28 is a table of the measurement data for the rate of changeunder load of another slightly loose toilet paper roll;

[0077]FIG. 29 is a table of the measurement data for the rate of changeunder load of a toilet paper roll of regular tightness;

[0078]FIG. 30 is a table of the measurement data for the rate of changeunder load of a slightly tight toilet paper roll;

[0079]FIG. 31 is a table of the measurement data for the rate of changeunder load of a tight toilet paper roll;

[0080]FIG. 32 is a table comparing measurements for toilet paper rollunwinding noise;

[0081]FIG. 33 is a graph comparing measurements for toilet paper rollunwinding noise;

[0082]FIG. 34 is a table comparing familiar noises and noise levels;

[0083]FIG. 35 is a line diagram of the compressive load displacements ofpaper tubes of toilet paper rolls, comparing the product implemented inthe present invention and a conventional product;

[0084]FIG. 36 is a line diagram of the compressive load displacementsduring the manufacture of flat elliptical toilet paper rolls, comparingthe product implemented in the present invention and a conventionalproduct;

[0085]FIG. 37 is a view showing a compressive load displacementexperiment performed during manufacture of the toilet paper roll of thepresent invention;

[0086]FIG. 38A is a view showing a single unit of the product of thepresent invention in a wrapped state;

[0087]FIG. 38B is a view showing the products of the present inventionwrapped in parallel;

[0088]FIG. 39 is a view showing a compressive load displacementexperiment performed during manufacture of the toilet paper roll of thepresent invention;

[0089]FIG. 40A is a view showing a single unit of the product of thepresent invention in a wrapped state;

[0090]FIG. 40B is a view showing the products of the present inventionwrapped in parallel;

[0091]FIG. 41A is a perspective view of a toilet paper roll cartonholding six of the toilet paper rolls of the present invention in awrapped state;

[0092]FIG. 41B is a lateral cross section of FIG. 41A;

[0093]FIG. 41C is a lateral cross section of a different embodiment tothat in FIG. 41B;

[0094]FIG. 42A is a perspective view of a toilet paper roll cartonholding six conventional toilet paper rolls in a wrapped state;

[0095]FIG. 42B is a lateral cross section of FIG. 42A;

[0096]FIGS. 43A through 43D are views showing [a process in which] aconventional flat toilet paper roll is returned to its original state;

[0097]FIG. 44A shows a state in which a compressive load displacementexperiment is about to begin during the manufacture of a conventionaltoilet paper roll;

[0098]FIG. 44B shows the locations of the compression points of yieldduring the experiment of FIG. 44A; and

[0099]FIG. 44C shows the final stage of the experiment of FIG. 44A.

BEST MODE FOR CARRYING OUT THE INVENTION

[0100] The present invention will be described below with reference tothe drawings.

[0101] In a first embodiment, as is illustrated in FIGS. 1 and 2, atoilet paper roll is constituted by a thick tubular core 1 which is madeof thin paper and has a diameter of approximately 4 cm, and toilet paper2 which is wound around the thick tubular core 1 substantially looselyfrom beginning to end. The thickness of the thick tubular core 1 inFIGS. 1A, 1C and 2A is thicker than the thickness of the toilet paper 2,but the thick tubular core 1 is manufactured from thin paper andconsequently is expressed in the drawings only by a line. This appliessimilarly to the second through ninth embodiments hereinbelow. FIG. 1Bin particular shows that the paper thickness of the thick tubular core 1is thicker than the paper thickness of the toilet paper 2. Theaforementioned toilet paper roll indicates a finished product in whichthe toilet paper 2 is formed into a roll. The aforementioned toiletpaper 2 indicates paper of appropriate length and includes paper ineither a rolled or unrolled form. As is illustrated in FIG. 1A, thetoilet paper roll as a finished product may be sold in a state in whicha circular cross section is maintained, or, due to the looseness of theentire product, may be sold in a flat elliptical form, as is illustratedby the dot/dash line in FIG. 1C. FIG. 2C is a schematic view of one partof FIG. 2A, and illustrates the entire height Ho of the wound toiletpaper 2 (subject to no load) when wound substantially loosely. In otherwords, gaps occur between the layers of wound toilet paper 2.

[0102] The thick tubular core 1 is manufactured from thin paper and hasan inner diameter of approximately 4 cm (specifically a diameter ofapproximately 3.8 cm to approximately 4.5 cm), and is manufactured byoverlapping a plurality of thin paper sheets, generally of approximately30 (g/m²) (weight in grams per 1 m² of paper) through 100 (g/m²),twisting these sheets into a spiral form, and joining the sheets usingan adhesive. In so doing, the weight of the regular paper alone cannotbe measured, and therefore the weight of the thick tubular core 1 withan inner diameter of approximately 4 cm is measured in widths of onetoilet paper roll (approximately 11 cm). According to this measurement,the weight of the thick tubular core 1, including the weight of glue andthe like, was between approximately 1 (g/roll) and 3 (g/roll). Thematerial for the thin paper of the thick tubular core 1 includes bothwater-soluble percolation paper and non-percolation paper that isunlikely to dissolve in water, or water-soluble percolation paper only.Thus, when no limitations are placed on the material for the thicktubular core 1, percolation paper and non-percolation paper are referredto. The aforementioned toilet paper 2 is percolation paper generallyweighing from approximately 16 (g/m²) to approximately 23 (g/m²). In theaforementioned inner diameter of approximately 4 cm, diameters fromapproximately 3 cm up to 5 cm are included. The material for the thicktubular core 1 typically differs from the material for the toilet paper2. Here, the thick tubular core 1 is manufactured from thin paper.Although paper of approximately 70 (g/m²) to 100 (g/m²) does notgenerally lie within the concept of thin paper, in this specificationparticularly, the thick tubular core 1 uses woodfree paper with ageneral weight of approximately 30 (g/m²) to 100 (g/m²), as opposed tothe cardboard used as the material for marketed paper tube cores, whichgenerally weighs from approximately 200 (g/m²) to approximately 220(g/m²), and is therefore referred to as being manufactured from thinpaper. The toilet paper roll of a second embodiment, as illustrated inFIG. 3, is one in which toilet paper 2 is initially wound tightly arounda thick tubular core 1 made of thin paper and with a diameter of around4 cm, and thereafter wound loosely to the end, thus being substantiallyloosely wound as a whole. “Substantially loosely wound as a whole” isequivalent to the previously mentioned “wound substantially loosely frombeginning to end”, and cases to be mentioned hereinbelow are similar.FIG. 3C is a partial schematic diagram of FIG. 3A, and illustrates atightly wound region H₂ and a substantially loosely wound region H₃within the entire height H₀ of the wound toilet paper 2 (when subject tono load). Hence, H₂+H₃=H₀.

[0103] The toilet paper roll in a third embodiment is comprised bytoilet paper 2, one part of which, excluding the initial part, is woundtightly around a thick tubular core 1 made of thick paper and with adiameter of around 4 cm, and the remainder thereof is woundsubstantially loosely, thus being wound substantially loosely as awhole. Specifically, as is illustrated in FIG. 4, this is a case inwhich the final few turns are wound tightly but the turns in all theother positions are wound substantially loosely. This type of winding isalso indicated by “wound substantially loosely as a whole”. Further,although not shown in the drawing, several turns may be wound tightly inan intermediate position in the toilet paper roll and the turns in allof the other positions wound substantially loosely. This also qualifiesas “being wound substantially loosely as a whole”. FIG. 4C is a partialschematic diagram of FIG. 4A in which a tightly wound region H₄ and asubstantially loosely wound region H₅ are illustrated within the entireheight Ho of the wound toilet paper 2 (when subject to no load). Hence,H₄+H₅=H₀.

[0104] Further, in a fourth embodiment, as is illustrated in FIGS. 10and 11, the toilet paper roll is constituted by a thick tubular core 1manufactured from thin paper and having a diameter of approximately 4cm, and toilet paper 2 which is wound substantially loosely around thethick tubular core 1 from beginning to end. As is shown in FIG. 10C, thethick tubular core 1 is formed into a flat shape, and the toilet paper 2is also formed in a flat elliptical shape in compliance with the flatthick tubular core 1. The toilet paper roll as a finished product isillustrated in FIG. 10C. FIG. 10A shows a semi-manufactured productdirectly after the toilet paper 2 has been wound around the thicktubular core 1. Further, in the fourth through ninth embodiments of thisspecification, referring simply to the thick tubular core 1 indicatesboth the circular form (see FIG. 1A) and the flat form (see the unbrokenline in FIG. 10C). Moreover, referring simply to the toilet paper 2indicates paper of appropriate length and includes paper in either arolled or unrolled form.

[0105] In a fifth embodiment, as is illustrated in FIG. 12, the toiletpaper roll is formed such that toilet paper 2 is initially wound tightlyaround a thick tubular core 1 made of thin paper and with a diameter ofaround 4 cm, and thereafter wound substantially loosely so as to bewound substantially loosely as a whole. The thick tubular core 1 isformed into a flat shape, and the toilet paper 2 is also formed into aflat elliptical shape in compliance with the elliptical thick tubularcore 1. FIG. 12C is a partial schematic diagram of FIG. 12A. In FIG. 12,the entire height H₀ (when subject to no load), the region H₂ and theregion H₃ are similar to those in FIG. 3. The unbroken line in FIG. 12Aindicates a semi-manufactured toilet paper roll, and the dot/dash linetherein indicates the toilet paper roll as a finished product.

[0106] The toilet paper roll in a sixth embodiment, as illustrated inFIG. 13, is formed such that one part of the toilet paper 2, excludingthe initial part, is wound tightly around a thick tubular core 1 made ofthin paper and with a diameter of around 4 cm, and the remainder thereofis wound substantially loosely around the thick tubular core 1, thusbeing wound substantially loosely as a whole. The thick tubular core 1is formed into a flat shape, and the toilet paper 2 is also formed intoa flat elliptical shape in compliance with the flat thick tubular core1. Specifically, as shown in FIG. 13, the final few turns may be woundtightly, with the turns in all of the other positions woundsubstantially loosely. In FIG. 13, the entire height H₀ (when subject tono load), the region H₄ and the region H₅ are similar to those of FIG.4. In FIG. 13A also, the unbroken line indicates a semi-manufacturedtoilet paper roll, and the dot/dash line therein indicates the toiletpaper roll as a finished product.

[0107] In order to manufacture the toilet paper roll of the fourth tosixth embodiments, the two following types of manufacturing method areemployed. In a first manufacturing method, the thick tubular core 1 isinitially inserted into a roller shaft in perfect circle form. In thisstate, the toilet paper 2 is wound substantially loosely around thethick tubular core 1 from beginning to end, upon completion of which asemi-manufactured toilet paper roll aggregate body (i.e. between 10 and20 semi-manufactured toilet paper rolls joined together with a circularcross section) is produced. Next, the roller shaft is removed from thesemi-manufactured toilet paper roll aggregate body. In the followingprocess, the top and bottom (see unbroken line in FIG. 1A) or both sidesof the cross section of the semi-manufactured toilet paper roll arepushed inward to form the cross section of the thick tubular core 1 intoa flat shape, and also to form the toilet paper 2 into a flat ellipticalshape in compliance with the flat thick tubular core 1 (see dot/dashline in FIG. 11A).

[0108] In a second manufacturing method, pressure is applied to theentire cross section of the toilet paper roll of the fourth throughsixth embodiments so as to form the roll into a flat elliptical shape.However, this may be achieved with only slight pressure, and thereforethere are cases in which this process is performed on asemi-manufactured toilet paper roll and cases in which the toilet paperroll as a finished product is formed into a flat elliptical shape bypushing in both sides with guides on both sides which are used in thewrapping process.

[0109] The toilet paper roll in a seventh embodiment, as is illustratedin FIGS. 15 and 16, is constituted by a thick tubular core 1 which ismanufactured from thin paper and has a diameter of approximately 4 cm,and toilet paper 2 which is wound substantially loosely around the thicktubular core 1 from beginning to end. As is shown in FIG. 15C, the thicktubular core 1 is formed into a substantially flat shape having expandedportions 1 a, 1 a on both sides thereof in the form of a sycamore seed,and the toilet paper 2 is also formed into a flat elliptical shape incompliance with the flat thick tubular core 1. The toilet paper roll asa finished product is shown in FIG. 15C. FIG. 15A shows thesemi-manufactured product directly after the toilet paper 2 has beenwound onto the thick tubular core 1. The gaps that are produced betweenthe layers of wound toilet paper 2 are as in the first embodiment.

[0110] The toilet paper roll in an eighth embodiment, as is illustratedin FIG. 17, is formed such that toilet paper 2 is initially woundtightly around a thick tubular core 1 made of thin paper and with adiameter of around 4 cm, and thereafter wound substantially loosely soas to be wound substantially loosely as a whole. The thick tubular core1 is formed into a substantially flat shape having expanded portions 1a, 1 a on both sides thereof in the form of a sycamore seed, and thetoilet paper 2 is also formed into a flat elliptical shape in compliancewith the flat thick tubular core 1. FIG. 17C is a partial schematicdiagram of FIG. 17A, and the entire height Ho (when subject to no load),the region H₂ and the region H₃ in FIG. 17 are similar to those in FIG.3. The unbroken line in FIG. 17A indicates a semi-manufactured toiletpaper roll, whereas the dot/dash line therein indicates the toilet paperroll as a finished product.

[0111] The toilet paper roll in a ninth embodiment, as is illustrated inFIG. 18, is formed such that one part [of the toilet paper 2], excludingthe initial part, is wound tightly around a thick tubular core 1 made ofthin paper and with a diameter of around 4 cm, and the remainder thereofis wound substantially loosely around the thick tubular core 1, thusbeing wound substantially loosely as a whole. The thick tubular core 1is formed into a substantially flat shape having expanded portions 1 a,1 a on both sides thereof in the form of a sycamore seed, and the toiletpaper 2 is also formed into a flat elliptical shape in compliance withthe flat thick tubular core 1. More specifically, as shown in FIG. 18,the final few turns are wound tightly, and the turns in all of the otherpositions are wound substantially loosely. The entire height H₀ (whensubject to no load), the region H₄ and the region H₅ in FIG. 18 aresimilar to those in FIG. 4. The unbroken line in FIG. 13A also indicatesa semi-manufactured toilet paper roll, whereas the dot/dash lineindicates the toilet paper roll as a finished product.

[0112] In order to-manufacture the toilet paper roll of the seventh toninth embodiments, the following two types of manufacturing method areemployed. A third manufacturing method uses a flattening device M shownin FIG. 20. This flattening device M is for positioning thesemi-manufactured toilet paper rolls after the semi-manufactured toiletpaper roll aggregate body has been cut into individual toilet paperrolls by a cutter N. To explain this manufacturing method specifically,as shown in FIGS. 21 through 23, the circular semi-manufactured toiletpaper rolls are transported onto the flattening device M, and in thisposition a conveyor 25 stops (see FIG. 21A). Simultaneously, twohole-widening round bars 30, 30 which are clamped by front side positionclamp portions 31, 31, are inserted into the thick tubular core 1 of thesemi-manufactured toilet paper roll (see FIG. 21B). Next, thehole-widening round bars 30, 30 are clamped at the rear end side thereofby rear side position clamp portions 31, 31 (see FIGS. 21C and 21D). Inthis state, the upper hole-widening round bar 30 is raised (see FIGS.21E and 21F) such that the shape of the hole in the thick tubular core 1is altered to a vertical flat ellipse (see FIG. 22A). In this state, thesemi-manufactured toilet paper roll is pressed inward from the left andright by pressing portions 33, 33 on the ends of rods 32 a, 32 a ofhydraulic cylinders 32, 32 (predominantly pneumatic cylinders) (seeFIGS. 22B and 23), thereby forming fig-like expanded portions 1 a, 1 aon both sides (in FIG. 22 on the top and bottom) of the thick tubularcore 1. Hence, the entire thick tubular core 1 is formed into asubstantially flat shape, and the toilet paper 2 also takes on a flatelliptical shape in compliance with the flat thick tubular core 1, thuscompleting the molding [process].

[0113] The front side position clamp portions 31, 31 are then removed,and at the same time the toilet paper roll finished product istransported on the now moving conveyor 25 to the wrapping machine C side(see FIG. 22C). Next, the two hole-widening round bars 30, 30 which areclamped by the rear side position clamp portions 31, 31 make a reverseturn such that the rear side position clamp portions 31, 31 become frontside position clamp portions 31, 31 (see FIG. 22D). The upperhole-widening round bar 30 is lowered to return to its original position(see FIG. 22E), whereby, returning to FIG. 21A, the nextsemi-manufactured toilet paper roll undergoes flattening. Duringtransportation of the toilet paper roll finished product, the shape ofthe flattened toilet paper roll is maintained by a curved guide 26 and astraight guide 27 (see FIG. 20B). At the front and rear of theflattening machine M, the toilet paper roll is transported along aconveyor 23 and supported by straight guides 24, 24 on both sides.

[0114] In order to manufacture the toilet paper roll of the seventh toninth embodiments using a fourth manufacturing method, a flatteningdevice X in FIG. 24 is used instead of the flattening device M.Specifically, the flattening device X is provided with upper and lowerpressing support plates 40, 40 and left and right-side hydrauliccylinders 41, 41 (predominantly pneumatic cylinders) (see FIG. 24A). Inthis operation, [the semi-manufactured toilet paper roll] is pressedinward by pressing portions 42, 42 on the ends of rods 41 a, 41 a of thehydraulic cylinders 41, 41, simultaneously being supported by the upperand lower pressing support plates 40, 40 (see FIG. 24B). Thereby,sycamore seed-type expanded portions 1 a, 1 a are formed in the upperand lower positions of the flattened thick tubular core 1, and hence theentire thick tubular core 1 is formed into a substantially flat shape,and the toilet paper 2 also takes on a flat elliptical shape incompliance with the flat thick tubular core 1, thus completing themolding [process].

[0115] The above product of the present invention is used when mountedon a thick shaft portion 10 of a toilet paper roll holder. Theaforementioned “wound substantially loosely from beginning to end” and“wound substantially loosely as a whole” indicate that the amount of airgaps between the layers of toilet paper 2 has been increased. As aresult of this increase in the amount of air gaps, when toilet paperwhich is mounted on the thick shaft portion 10 of the toilet paper rollholder is pulled, the toilet paper roll rotates such that the thicktubular core 1 and the thick shaft portion 10 of the toilet paper rollholder contact each other irregularly, whereby the toilet paper rollgenerates an unwinding noise. Nevertheless, the toilet paper 2 which is“wound substantially loosely from beginning to end” or “woundsubstantially loosely as a whole” exists around the thick tubular core1, and thus, by means of the air gaps between the layers of toiletpaper, this noise is eliminated or reduced without reaching the outside(see the S portion in FIG. 5A and FIG. 5B). Furthermore, since the thicktubular core 1 is made of thin paper and the toilet paper 2 that is“wound substantially loosely from beginning to end” or “woundsubstantially loosely as a whole” exists on the thick tubular core 1,one location on the thick tubular core 1 of the toilet paper rollbecomes flattened when the toilet paper 2 is unrolled (pulled) (see FIG.5A). Further, at this point in time, the thick tubular core 1 and thethick shaft portion 10 are in close contact at a shaft side point PC2and a tube side point P_(O2), whereas no contact is made at a shaft sidepoint P_(C1) and a tube side point P_(O1), as is illustrated in FIG. 6A.In the next moment, contact continues to be made at the shaft side pointP_(C2) and tube side point P_(O2), while contact is also made at theshaft side point P_(C1) and tube side point Po_(O1). Thus, duringrotation, contact is made as a surface. In this manner, surface contactis made due to the looseness [of the toilet paper roll], whereby eitherno noise or an extremely soft sound is produced. On the other hand, asis illustrated in FIG. 7, in a cardboard tube core a of a conventionaltoilet paper roll, at one moment there are points which contact thethick shaft portion 10, and a shaft side point P_(C) and a tube sidepoint P_(O) which do not make contact. At the next moment, however, theshaft side point P_(C) and tube side point P_(O) contact each other butthe points that were previously in contact separate from each other.Thus, during rotation, contact is made at points, and in this state ofpoint contact a large unwinding noise is generated in the toilet paperroll. The product of the present invention solves such a disadvantage bythe surface contact action shown in FIG. 6.

[0116] As described above, the product of the present invention is ableto drastically reduce unwinding noise in a toilet paper roll because theincrease in the amount of air gaps between the layers of the toiletpaper 2 and the surface contact of the loose surfaces actsynergistically.

[0117] Further, as shown in FIG. 9, the percolation paper that is thematerial of the thick tubular core 1 has a water-soluble property, andthus softens when holding water, thereby altering the form of the thicktubular core 1. Hence, a toilet can be prevented from blocking even whenthe thick tubular core 1 which remains on the thick shaft portion 10 ofa typical household toilet paper roll holder following use of a toiletpaper roll is flushed down the toilet.

[0118] Also, as is illustrated in FIG. 14A, the thick tubular core 1 ofthe product of the present invention is formed into a flat shape, andthe toilet paper 2 is formed into a flat elliptical shape in compliancewith the flat thick tubular core. Nevertheless, when mounted on thethick shaft portion 10 of a toilet paper roll holder, the toilet paperroll can be returned to a substantially perfect circle form. As isillustrated in FIGS. 14A through 14D, since the thick tubular core 1 ismade of thin paper and the toilet paper is “wound substantially looselyfrom beginning to end” or “wound substantially loosely as a whole”, thetoilet paper roll can be returned to a substantially perfect circle formdue to the synergistic action between the loose toilet paper 2 and thefact that almost no pressure [need be] applied even when the thicktubular core 1 is flattened since the thick tubular core 1 is made ofthin paper. Furthermore, even though the thick tubular core 1 is formedinto a substantially flat shape having fig-like expanded portions 1 a, 1a on both sides, and the toilet paper 2 is formed into a flat ellipticalshape in compliance with the flat thick tubular core 1, the expandedportions 1 a, 1 a on both sides create no kinks whatsoever in the thicktubular core 1 upon mounting onto the thick shaft portion 10 of thetoilet paper roll holder, and thus, the thick tubular core 1 can bereturned to a substantially perfect circular form.

[0119]FIG. 41A shows six of the toilet paper rolls of the presentinvention sealed in one carton. FIG. 41B shows the state of insertion ofthe toilet paper rolls in a lateral cross section of the carton. FIG.41C shows a cross section of the toilet paper roll carton in a case inwhich the thick tubular core 1 is formed into a substantially flat shapehaving fig-like expanded portions 1 a, 1 a on both sides. If theconventional type toilet paper roll cartons of FIGS. 42A and B arecompared with the toilet paper roll carton of the present invention inFIG. 41, it can be seen as a result of experiment that the surface areaof the lateral cross section of the product of the present invention isapproximately 30% to 40% smaller than that of the conventional product.

[0120] Experiment 1

[0121] In this specification, “wound substantially loosely” indicatesthat when a 13 kg load measuring weight 21 is applied to a toilet paperroll, the rate of change under load thereof is approximately 36% orgreater. This is according to the following experiment.

Rate of change under load=(H ₀ −H ₁)/H ₀×100

[0122] H₀: height when subject to no load

[0123] H₁: height when a 13 kg load measuring weight 21 is applied

[0124] In the experiment, as is shown in FIG. 25B, a measuring shaft 20was inserted into the thick tubular core 1 of the toilet paper rollmanufactured according to the present invention, the paper tube core ofa marketed toilet paper roll, or a toilet paper roll core, the height ofthe uppermost position on the periphery of the thick tubular core 1 etc.was set to 0, this was set as the reference height position, and theheight therefrom to the uppermost end position on the periphery of thetoilet paper 2 of the toilet paper roll with no load thereupon, or inother words the height of the toilet paper roll when subject to no load,was set as H₀. A 13 kg measuring weight 21 was placed upon the toiletpaper roll subject to no load, and at that time, the gaps between thelayers of toilet paper 2 became narrower due to the measuring weight 21,thereby reducing the height. The height to the uppermost end position onthe periphery of the toilet paper 2 at this time, or in other words theheight upon application of a 13 kg load, was set as H₁.

[0125] In the experiment, the following were used for rate of changeunder load measurement data: the product of the present invention (seeFIG. 26); loosely wound with core A (see FIG. 27) and looselywoundwithcore B (see FIG. 28), which were chosen appropriately with texture as areference and are wound slightly loosely at their center; normally woundwith core (see FIG. 29) in which the surface turns are wound at a normallevel of tightness; tightly wound with core (see FIG. 30) which is woundslightly tightly; and tightly wound no core (see FIG. 31) which is woundtightly. The H₀ and H₁ of this plurality of samples were measured. Theresulting measurement data are shown in FIGS. 26 through 31, and themaximum rate of change under load, average rate of change, and minimumrate of change are gathered and shown in FIG. 25A. When made into acomparison graph, such as FIG. 25C, the following can be observed.

[0126] That is, “tightly wound” indicates a rate of change under load of0% to approximately 9%; “slightly tightly wound” indicates a rate ofchange under load of approximately 9% to approximately 21%; “wound to anormal level of tightness” indicates a rate of change under load ofapproximately 21% to approximately 36%; “slightly loosely wound”indicates a rate of change under load of approximately 36% toapproximately 49%; and “loosely wound” indicates a rate of change underload of approximately 49% or greater. Thus, since “substantially looselywound” includes “loosely wound” and “slightly loosely wound”, thepreviously mentioned “substantially loosely wound” indicates that undera load of 13 kg, the rate of change under load is approximately 36% orgreater. This value may vary by approximately 10% depending on thetemperature, humidity, air pressure and so on in the placement conditionof the toilet paper roll.

[0127] Further, the (H₀−H₁) of the previous equation also expresses theamount of air gaps between the layers of the toilet paper 2 in thetoilet paper roll, and therefore the rate of change under load accordingto this equation can be said to be substantially equal to the air gapratio. Accordingly, an air gap ratio of approximately 36% or greater canbe said to be “wound substantially loosely”. It is important to notehere that the surface load is 13 kg. With an 18 kg measuring weight 21,the value of (H₀−H₁) increases such that the rate of change under loadincreases for all of the categories of winding method. Thereby, a rateof change under load of approximately 40% or greater indicates “woundsubstantially loosely”. With a 7 kg measuring weight 21, for example,the value of (H₀−H_(l)) decreases such that the rate of change underload decreases for all of the categories of winding method. Thereby, arate of change under load of approximately 30% or more indicates “woundsubstantially loosely”.

[0128] Experiment 2

[0129] In an experiment shown in FIG. 32 to measure the unwinding noiseof the toilet paper roll of the present invention, the toilet paper rollof the present invention was compared with a conventional toilet paperroll with a typical cardboard paper tube core, whereby it was learnedthat the toilet paper roll of the present invention becomesprogressively quieter. To described the experiment specifically, thethick tubular core 1 relating to the present invention is made from thinpaper, has an inner diameter of approximately 3.8 cm, and weighsapproximately 1.6 g per length of toilet paper roll (approximately 11cm). The thick tubular core 1 is formed from two thin paper sheets ofapproximately 50 (g/m²) which are appropriately twisted into spiral formand overlapped. Water-soluble percolation paper is used as the materialfor the thin paper of the thick tubular core 1. As the conventionalproduct, a so-called normally wound with core toilet paper roll wasused, wound at a normal level of tightness onto a cardboard paper tubecore with an inner diameter of approximately 3.8 cm. Both the toiletpaper roll of the present invention, manufactured with toilet paper 2which is “loosely wound” and the conventional normally wound with coretoilet paper roll were set with outer diameters of approximately 110 mm.The toilet paper rolls were mounted onto the thick shaft portion 10 of atypical household one touch-type toilet paper roll holder, the lid ofthe toilet paper roll holder was removed so as to eliminate contactnoise between the lid and the toilet paper, and the unwinding noisegenerated when pulling the toilet paper was measured. Measurement wasperformed with a sound sensor disposed at approximately 50 cm, 1 m, and1.5 m from the location of the toilet paper roll holder. Even if theunwinding rate of the toilet paper is constant, the toilet paper roll isunwound from the outer periphery side, and therefore the rate is slow atthe peripheral portion which has a large outer diameter, and the rateincreases as the diameter grows smaller toward the central portion.Consequently, measurement was performed at three locations, theperipheral portion, an intermediate portion, and the central portion (atthe thick tubular core side).

[0130] As is shown in the table in FIG. 32, the unwinding noise grewquieter by between 12 dB (decibels) and 17 dB in all of the peripheralportion, intermediate portion, and central portion (at the thick tubularcore side) positions. In a toilet or the like, it is normal for anotherperson to be removed by at least lm, and hence, taking an average of thetwo samples, [the noise level of] the conventional normally wound withcore-type was 65 dB, and the product of the present invention was 53 dB.Although the difference is only 12 dB, decibels express sound levels aslogarithms, and hence a difference of 10 dB corresponds to a sound levelthat is 10 times higher. In other words, the progressive differences areas follows: a difference of 12 dB corresponds to a sound level that isapproximately 16 times higher; 13 dB corresponds to approximately 20times higher; 14 dB corresponds to approximately 25 times higher; 15 dBcorresponds to approximately 32 times higher; 16 dB corresponds toapproximately 40 times higher; and 17 dB corresponds to approximately 50times higher. Expressing the table in FIG. 32 as a graph results in FIG.33, wherein the differences in unwinding noise between the conventionalproduct and the product of the present invention become obvious. Byreferencing a comparative table of familiar noises and noise levels, asin FIG. 34, it can be seen that approximately 65 dB is in anintermediate position between a regular conversation and the sound of anoisy office or a telephone, whereas the approximately 53 dB of theproduct of the present invention is a sound close to a quiet office.Therefore, simply considering the level of noise, the difference isextremely striking. Thus, when the product of the present invention isused, the unwinding sound of the toilet paper roll becomes extremelysmall, and hence the toilet paper roll can be used freely, even bywomen, without anxiety.

[0131] Experiment 3

[0132]FIG. 35 is a line diagram of the compressive load displacements ofpaper tubes of toilet paper rolls (paper tube cores, the thick tubularcore 1 of the present invention and so on). The thick tubular core 1 ofthe present invention has an inner diameter of approximately 3.8 cm, andthick tubular cores 1 with weights per one length of toilet paper roll(approximately 11 cm) of 1.0 (g/roll), 1.6 (g/roll), 2.0 (g/roll), 2.4(g/roll) and 3.0 (g/roll) were used. Conventional cardboard paper tubecores of 5.9 (g/roll) and 6.4 (g/roll) were also used. Water-solublepercolation paper was used as the material for the thin paper of thethick tubular core 1. The aforementioned 1.0 (g/roll), 1.6 (g/roll), 2.0(g/roll), 2.4 (g/roll) and 3.0 (g/roll) thick tubular cores 1 are formedby two sheets of thin paper with respective weights of approximately 30(g/m²), approximately 50 (g/m²), approximately 65 (g/m²), approximately80 (g/m²), and approximately 100 (g/m²), twisted appropriately intospiral form and overlapped. Further, the conventional cardboard papertube cores of 5.9 (g/roll) and 6.4 (g/roll) are formed by two sheets ofthick paper respectively weighing approximately 200 (g/m²) andapproximately 220 (g/m²), twisted appropriately into spiral form andoverlapped. In this experiment, a load was applied to the thick tubularcore 1 and the paper tube core, having an inner diameter ofapproximately 3.8 cm, so as to cause height variations from 0 to 15 mm,and thus a line diagram of the compressive load displacements of thepaper tubes of toilet paper rolls was determined.

[0133] As is shown in FIG. 35, the results thereof indicate that the 2.0(g/roll) thick tubular core 1 of the present invention can be pressedinward with up to one twentieth of the force (N) required for the 6.4(g/roll) conventional cardboard paper tube core. Thus, as notedpreviously, the thick tubular core 1 can be crushed easily and with farless force than that required by a conventional cardboard paper tubecore (see FIG. 8). It can also be understood from FIG. 35 that woodfreepaper of up to approximately 3 (g/roll) is appropriate for the thinpaper used to manufacture the thick tubular core 1 of the presentinvention. Further, the weight of the thick tubular core 1 varies byapproximately 10% to 20% according to the amount of glue, and thereforewoodfree paper of up to approximately 4 (g/roll) may also be included inthe thin paper used to manufacture the thick tubular core 1 of thepresent invention.

[0134] Experiment 4

[0135]FIG. 36 is a line diagram of toilet paper roll compressive loaddisplacements upon the manufacture of the toilet paper rolls of thefourth through ninth embodiments of the present invention in particular.The thick tubular core 1 of the present invention has an inner diameterof approximately 3.8 cm, and a weight per one length (approximately 11cm) of toilet paper roll of 1.6 (g/roll). The toilet paper roll used iswound loosely and has an outer diameter of approximately 11 cm. A toiletpaper roll with a cardboard paper tube core weighing 6.4 (g/roll), whichis normally wound with a core and has an outer diameter of approximately11 cm, is used as marketed product a, and a toilet paper roll with acardboard paper tube core weighing 5.9 (g/roll), which is loosely woundwith a core and has an outer diameter of approximately 11 cm, is used asmarketed product b.

[0136] In the experiment, a compressive load was applied and theresulting displacement was measured. In this specification, there is afactor of error of approximately 2%, and 1 kgf is set as 10N (Newton).Hence, as is illustrated in FIG. 36, when a compressive load isgradually applied to the circular marketed product a, applyingapproximately 5N causes displacement of approximately 8 mm, and applyingapproximately 10N causes displacement of approximately 14 mm. Further,when the maximum compressive load of approximately 10.5N is applied,displacement of approximately 15 mm occurs (see FIG. 44B). Thereafter,the amount of displacement increases even when a compressive load whichis no more than the maximum compressive load is applied. At the pointwhen approximately 9.5N causes an approximately 50 mm displacement, thepaper tube core becomes flattened and the toilet paper is formed into aflat elliptical shape (see FIG. 44C). Further, in circular marketedproduct b, application of approximately 6N causes displacement of 20 mm,and approximately 10.2N causes displacement of 30 mm. When the maximumcompressive load of 10.5N is applied, displacement of 32 mm occurs (seeFIG. 44B), after which the amount of displacement increases even when acompressive load which is no more than the maximum compressive load isapplied. At the point when approximately 9.9N causes an approximately 60mm displacement, the paper tube core becomes flattened and the toiletpaper is formed into a flat elliptical shape (see FIG. 44C). Note thatin a tensile test, the point at which the amount of displacementincreases without increasing the tensile load is defined in JISterminology as the “yield point”. In the present invention, it is acompressive displacement experiment that is performed, but since theamount of displacement increases from the point of maximum compressiveload without adding to the compressive load, this maximum compressiveload point is referred to as the “compression yield point” in thisspecification. In this compressive displacement experiment, the heightof the marketed product a and marketed product b prior to shapealteration is set as Y₀, and the height thereof following compressioninto a flat elliptical shape is set as Y₂ (see FIG. 44).

[0137] In the present invention, as is shown in FIG. 36, the circularsemi-manufactured toilet paper roll is displaced by 18 mm whenapproximately 1N is applied, and by 30 mm when 2N are applied. When themaximum compressive load of approximately 4N is applied, the toiletpaper roll changes shape by approximately 42 mm of displacement, and atthis point the thick tubular core 1 becomes flattened and the toiletpaper 2 is formed into a flat elliptical shape. In this compressivedisplacement experiment, when the height of the circular toilet paperroll of the present invention prior to displacement is set as Y₀, theheight thereof following compression into a flat elliptical shapebecomes Y₁, and no compression occurs beyond the aforementioned heightY₂. Hence, height Y₁>height Y₂ (see FIGS. 37, 39 and 44). Further, thereis no compression yield point in the product of the present invention.In the marketed products a and b, the amount of displacement is large asa whole when moving from the state in FIG. 44B to that in FIG. 44C. Inother words, during the pressure-flattening operation of the paper tubecore in the compression process, a large amount of force is required atthe point where the paper tube core takes a rhomboid elliptical shapedue to the hardness of the cardboard paper tube core, and up to thatpoint the upper and lower layers of toilet paper 2 are pressed togetherand compressed (see FIG. 44B). The maximum value at this point is aprescribed value, and the point of this prescribed value is referred toas compression yield point K (see FIG. 36). From the point of thiscompression yield point K, the amount of displacement increases evenwithout increasing the pressure of the compressive load on thesemi-manufactured toilet paper roll above the prescribed value (in thegraph in FIG. 36, approximately 10N and 1.05 kgf). At this time, thepaper tube core is flattened and the degree of flatness of the toiletpaper increases further to form a flat elliptical shape.

[0138] As is illustrated in FIGS. 38 and 40, since only a small amountof pressure (compressive load) need be applied to flatten the thin paperthick tubular core 1 and form the loosely wound toilet paper 2 into aflat elliptical shape, the repulsive force f, f needed in order toreturn the toilet paper roll to its original circular form is alsosmall, and packaging by sealing the product into a bag 50 can beperformed easily. In the present invention, in the operation to form thetoilet paper 2 into a flat elliptical shape, the applied pressure ismerely up to 4N, and thus the toilet paper roll responds sufficientlywell to the application of pressure in the packaging process.Manufacture can also be easily accomplished at approximately 5N.

[0139] According to the present invention as described above, theunwinding noise of a toilet paper roll can be reduced considerably. Morespecifically, even if the toilet paper roll of the present invention ismounted onto the thick shaft portion of a typical household toilet paperroll holder or the like such that the thick shaft portion and the thicktubular core contact one another while rotating to produce contactnoise, squeaks or the like, this noise is eliminated or reduced withoutbeing transmitted to the outside due to the fact that the thick tubularcore is made of thin paper and therefore rotates in compliance with thetoilet paper roll holder so as to make surface contact therewith, anddue to the fact that toilet paper that is “wound substantially loosely”exists around the thick tubular core and air gaps exist between thelayers of the toilet paper. This fact was clearly proven in theexperiment in FIGS. 32 and 33. In this experiment, a reduction inunwinding noise of between approximately 12 dB and approximately 17 dBwas achieved. In actuality, however, almost no noise could be heard. Asa result, a silent-type toilet paper roll can be provided having thegreat advantage that unwinding noise such as rattling noise generatedwhen using the toilet paper in a toilet can be eliminated, whereby womenin particular can use the toilet paper without anxiety.

[0140] Furthermore, in the present invention, the thick tubular core ismanufactured from thin paper, and therefore has far less strength than aconventional cardboard paper tube core. As a result, even women andchildren can easily crush the thick tubular core which remains on thethick shaft portion of a typical household toilet paper roll holderafter use of the toilet paper roll (see FIG. 8). This has the advantagesof enabling a reduction in household refuse and allowing the thicktubular core to be disposed of as general refuse. Moreover, since thethick tubular core is manufactured from thin paper, this paper isthinner than that of a conventional cardboard paper tube core, and theamount of paper used is lower. Thus, the unit price of the core itselfcan be reduced. As a result, the entire toilet paper roll can beproduced at a comparatively reasonable price. Further, soft typecore-less toilet paper rolls exist in one part of the market, but theglued sections of the core have a damaged appearance, making itdifficult for such products to penetrate general markets. Alternatively,the machines for manufacturing these soft type core-less toilet paperrolls are special machines of a particular specification, meaning thatsuch toilet paper roll is comparatively extremely expensive to produce.In the present invention, however, the outer appearance of the papertube core is substantially identical in form to that of a typical papertube core, and the production costs thereof can be progressivelyimproved. Hence, in addition to the elimination of noise andfavorability in respect of refuse disposal as described above, the priceof a single unit of the product can be reduced.

[0141] Moreover, according to the present invention, since the thicktubular core is made of percolation paper and therefore has awater-soluble property, toilet blockages can be avoided even when thethick tubular core is flushed down the toilet after use. The toiletpaper roll of the present invention also has a flat elliptical shape,and therefore, in comparison with a conventional toilet paper roll inperfect circle form, has the advantages of greatly reducing space suchthat storage costs, transport costs and so on can be reduced.

INDUSTRIAL APPLICABILITY

[0142] The present invention may be used as a toilet paper roll in whichunwinding noise is greatly reduced even upon mounting onto the thickshaft portion of a typical household toilet paper roll holder, in whichthe thick tubular core of the toilet paper roll can be easily crushedand disposed of and is therefore favorable as regards refuse processing,in which the thick tubular core can also be manufactured reasonably suchthat the manufacturing cost of the toilet paper roll can also be reducedin price, in which the thick tubular core can also be flushed into thetoilet, in which moreover, since the toilet paper roll is manufacturedinto a flat elliptical form, storage costs, transport costs and the likecan be reduced, and in which during use, the cross section becomessubstantially circular such that the toilet paper roll is sufficientlyusable.

1. A toilet paper roll characterized in comprising: a thick tubular corewhich is manufactured from thin paper and has a diameter ofapproximately 4 cm; and toilet paper which is wound substantiallyloosely from beginning to end around this thick tubular core.
 2. Atoilet paper roll characterized in comprising: a thick tubular corewhich is manufactured from thin paper and has a diameter ofapproximately 4 cm; and toilet paper which is wound around this thicktubular core tightly in the initial several turns and thereafter woundsubstantially loosely to the end, thereby being wound substantiallyloosely as a whole.
 3. A toilet paper roll characterized in comprising:a thick tubular core which is manufactured from thin paper and has adiameter of approximately 4 cm; and toilet paper which is wound aroundthis thick tubular core tightly for several turns at a part excludingthe initial part and thereafter wound substantially loosely, therebybeing wound substantially loosely as a whole.
 4. The toilet paper rollaccording to claim 1, 2 or 3, characterized in that said thick tubularcore is manufactured from percolation paper.
 5. A toilet paper rollcharacterized in comprising a thick tubular core which is manufacturedfrom thin paper and has a diameter of approximately 4 cm and toiletpaper which is wound substantially loosely from beginning to end aroundthis thick tubular core, and characterized in that said thick tubularcore is formed into a flat shape and said toilet paper is also formedinto a flat elliptical shape in compliance with said flat thick tubularcore.
 6. A toilet paper roll characterized in comprising a thick tubularcore which is manufactured from thin paper and has a diameter ofapproximately 4 cm and toilet paper which is wound around this thicktubular core tightly in the initial several turns and thereafter woundsubstantially loosely to the end, thereby being wound substantiallyloosely as a whole, and characterized in that said thick tubular core isformed into a flat shape and said toilet paper is also formed into aflat elliptical shape in compliance with said flat thick tubular core.7. A toilet paper roll characterized in comprising a thick tubular corewhich is manufactured from thin paper and has a diameter ofapproximately 4 cm and toilet paper which is wound around this thicktubular core tightly for several turns at a part excluding the initialpart and thereafter wound substantially loosely, thereby being woundsubstantially loosely as a whole, and characterized in that said thicktubular core is formed into a flat shape and said toilet paper is alsoformed into a flat elliptical shape in compliance with said flat thicktubular core.
 8. The toilet paper roll according to claim 5, 6 or 7,characterized in being formed such that during the formation of saidtoilet paper into a flat elliptical shape, there is no compression yieldpoint at which, when a compressive load of a prescribed value is appliedto a semi-manufactured toilet paper roll, the amount of displacementincreases even without applying further pressure, and such that theamount of displacement only increases under pressure that increasesgradually in the range of half or less the compressive load of saidprescribed value.
 9. A toilet paper roll characterized in comprising athick tubular core which is manufactured from thin paper and has adiameter of approximately 4 cm and toilet paper which is woundsubstantially loosely around this thick tubular core from beginning toend, and characterized in that said thick tubular core is formed into asubstantially flat shape having fig-like expanded portions on bothsides, and said toilet paper is also formed into a flat elliptical shapein compliance with said substantially flat thick tubular core.
 10. Atoilet paper roll characterized in comprising a thick tubular core whichis manufactured from thin paper and has a diameter of approximately 4 cmand toilet paper which is wound around this thick tubular core tightlyin the initial several turns and thereafter wound substantially looselyto the end, thereby being wound substantially loosely as a whole, andcharacterized in that said thick tubular core is formed into asubstantially flat shape having fig-like expanded portions on bothsides, and said toilet paper is also formed into a flat elliptical shapein compliance with said substantially flat thick tubular core.
 11. Atoilet paper roll characterized in comprising a thick tubular core whichis manufactured from thin paper and has a diameter of approximately 4 cmand toilet paper which is wound around this thick tubular core tightlyfor several turns at a part excluding the initial part and thereafterwound substantially loosely, thereby being wound substantially looselyas a whole, and characterized in that said thick tubular core is formedinto a substantially flat shape having fig-like expanded portions onboth sides, and said toilet paper is also formed into a flat ellipticalshape in compliance with said substantially flat thick tubular core. 12.The toilet paper roll according to claim 9, 10 or 11, characterized inbeing formed such that during the formation of said toilet paper into aflat elliptical shape, there is no compression yield point at which,when a compressive load of a prescribed value is applied to asemi-manufactured toilet paper roll, the amount of displacementincreases even without applying further pressure, and such that theamount of displacement only increases under pressure that increasesgradually in the range of half or less the compressive load of saidprescribed value.
 13. A manufacturing method for a toilet paper roll,characterized in comprising the steps of: manufacturing asemi-manufactured toilet paper roll comprising a thick tubular corewhich is made of thin paper and which has a diameter of approximately 4cm, and toilet paper which is wound substantially loosely as a wholearound this thick tubular core; fixing and supporting thissemi-manufactured toilet paper roll in a substantially outer diametricalposition with facing pressing support plates; and pressing thesemi-manufactured toilet paper roll inward at a substantially centralposition in the two substantially orthogonal directions to the directionof spacing between the two pressing support plates using pressingportions on the ends of hydraulic cylinders, whereby the thick tubularcore is formed into a substantially flat shape as a whole while formingfig-like expanded portions on the two end positions of the substantiallyflat thick tubular core, and the toilet paper is also formed into a flatelliptical shape in compliance with said substantially flat thicktubular core.
 14. A manufacturing method for a toilet paper roll,characterized in comprising the steps of: manufacturing asemi-manufactured toilet paper roll comprising a thick tubular corewhich is made of thin paper and which has a diameter of approximately 4cm, and toilet paper which is wound substantially loosely as a wholearound this thick tubular core; and stretching said thick tubular coreby inserting two hole-widening round bars therein for forming said thicktubular core into a flat elliptical shape while pressing said thicktubular core inward from both sides using hydraulic cylinders indirections which are orthogonal to the spacing between said twohole-widening round bars while, whereby the thick tubular core is formedinto a substantially flat shape as a whole while forming fig-likeexpanded portions on the two end positions of the substantially flatthick tubular core, and the toilet paper is also formed into a flatelliptical shape in compliance with said substantially flat thicktubular core.